Seat construction

ABSTRACT

A seat construction comprising a frame including a base and a back. Each of the base and back have a frame with spaced side rails and a spring assembly mounted on the frame. Each spring assembly comprises a plurality of longitudinally extending wires, a plurality of transversely spaced wires having intermediate portions extending between the spaced wires and free ends extending beyond the longitudinally extending wires at an acute angle to the intermediate portion. Each spring assembly further comprises a longitudinal wire along each side edge connecting the free ends of said transversely spaced wires. Each spring assembly is embedded in a body of resilient foam plastic material.

[4 1 Apr. 17, 1973 SEAT CONSTRUCTION [75] Inventor: Henry J. Tischler,Bloomfield Hills,

Mich.

[73] Assignee: Gulf & Western Metals Forming Company, Southfield, Mich.

221 Filed: Sept. 16, 1971 [21] Appl. No.: 181,041

Related US. Application Data [63] Continuation-impart of Ser. No.25,832, April 6,

I 1970, Pat. No. 3,639,002.

297/DlG. l, DIG. 2, 218, 219

[56] ReferencesCited UNITED STATES PATENTS 3,529,866 9/1970 Getz..297/458X 3,630,572 12/1971 Homien ..297/454 3,632,164 1/1972 Homier..297/452 3,537,752 3/ 1970 Kushnarou et al. ..297/456 PrimaryExaminer-Casmir A. Nunberg Att0meyBames, Kisselle, Rasich & ChoateABSTRACT A seat construction comprising a frame including a base and aback. Each of the base and back have a frame with spaced side rails anda spring assembly mounted on the frame. Each spring assembly comprises aplurality of longitudinally extending wires, a plurality of transverselyspaced wires having intermediate portions extending between the spacedwires and free ends extending beyond the longitudinally extending wiresat an acute angle to the intermediate portion. Each spring assemblyfurther comprises a longitudinal wire along each side edge connectingthe free ends of said transversely spaced wires. Each foam plasticmaterial.

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INVENTOR HENRY J. TISCHLER v BY ATTORNE V5 PATENTEUAPRHI SHEET 3 OF 4INVENTOR. TISCHL ER HENRY J.

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SHEET 4 [IF 4 INVENTOR. HENRY J. T\SCHLER A T TORNE Y5 SEAT CONSTRUCTIONThis application is a continuation-in-part of application Ser. No.25,832, filed Apr. 6, 1970 now U.S. Pat. No. 3,639,002, issued Feb. I,1972.

This invention relates to seat construction and particularly to springseat construction.

Conventional types of seat construction comprise coiled springs, sinuoussprings, combinations of coiled and sinuous springs and the like.

In the aforementioned patent application there is provided a novelspring assembly that comprises a plurality of longitudinally extendingwires, a plurality of transversely spaced spring wires havingintermediate portions, extending between the spaced longitudinal wires,and free ends extending beyond the longitudinally extending wires at anacute angle to the intermediate portions. A longitudinal wire isprovided along each side edge connecting the free ends of thetransversely spaced wires. Such a construction obviates the need forcoiled and sinuous springs in the spring assembly. The spring assemblyis preferably embedded in a body of foam plastic material.

Among the objects of the invention are to provide an improved seatconstruction of the type shown in the aforementioned patent-application;which utilizes longitudinally and transversely extending straight wiresconnected to form a spring assembly which is resiliently mounted on aframe, which seat construction is thinner than conventionalconstructions and yet at the same time produces the same luxurious feelon the occupant; which can be produced at low cost; which eliminatesparts and which can be readily adjusted to produce varying degrees ofresiliency and support.

SUMMARY OF THE INVENTION In accordance with the invention, the seatconstruction comprises a frame including a base and: a back. Each of thebase and back have a frame with spaced side rails and a spring assemblymounted on the frame. Each spring assembly comprises a plurality oflongitudinally extending wires, a plurality of transversely spaced wireshaving intermediate portions extending between the spaced wires. andfree ends extending beyond the longitudinally extending wires at anacute angle to the intermediate portion. Each spring assembly furthercomprises a longitudinal wire along each side edge connecting the freeends of said transversely spaced wires.

The spring assembly is embedded in a body of foam plastic material andis mounted directly on the frame of the base or back, being retained inposition by interengaging portions of the body and frame and by theupholstering material that is connected to the frame.

DESCRIPTION OF'THE DRAWINGS FIG. 1 is a fragmentary side elevationalview of a seat embodying the invention.

FIG. 2 is a part sectional plan view of the seat base, beforeupholstering.

FIG. 3 is a fragmentary sectional view on an enlarged scale taken alongthe line 33 in FIG. 2.

FIG. 4 is a fragmentary sectional view taken along the line 4-4 in FIG.2.

FIG. 5 is a fragmentary plan'view of a portion of a spring assemblyutilized in the seat.

FIG. 6 is a fragmentary plan view of another portion of the springassembly.

FIG. 7 is a fragmentary sectional view similar to FIG. 3 showingupholstering applied to the seat.

FIG. 8 is a fragmentary bottom plan view of a portion of the seat.

FIG. 9 is a fragmentary sectional view on an enlarged scale taken alongthe line 99 in FIG. 2.

FIG. 10 is a fragmentary plan view of another portion of the seat. I

DESCRIPTION Referring to FIG. 1, the seat embodying the inventioncomprises a seat base 10 and a seat back 11 that may be fixed or pivotedrelative to one another by appropriately mounting their frames inaccordance with well-known construction.

Each of the seat base 10 and seat back 11 is generally similarconstruction.

Referring to FIGS. 1 and 3, the seat base 10 comprises a frame 12including spaced side and front rails 13, made of sheet metal. The seatbase 10 further comprises a spring assembly 14 that is mounted on therails 13 as presently described.

Spring assembly 14 comprises spaced longitudinally extending wires 16 ofsteel having a paper wrapping l7 and spaced transversely extending wires18 of oil-tem-. pered spring steel. Wires 18 include intermediateportions 19, the ends of which are wound around the wires 16 (FIG. 5)and extend in a free manner as at 20 at an acute or obtuse angle to thegeneral plane of the intermediate portions 18 (FIG. 3). The free ends ofportions 20 are attached by a single loop about additionallongitudinally spaced wires 21 having a paper wrapping (FIG. 6). Theends of the longitudinally extending wires 21 can be interconnected by atransverse wire 23 (FIG. 2).

The spring assembly further comprises a body 25 in which the springassembly is embedded by molding foam plastic material about the springassembly.

As shown in FIGS. 2-4, the body 25- comprises a central portion 26 andupwardly extending'side portions 27 connected to one another by a narrowportion 28 defining grooves 28, which are spaced from and overlielongitudinally extending wires 16. The body 25 thus takes on abucket-type configuration.

The spring assembly 14 is embedded in the body in such a manner that theintermediate portions 19 are adjacent but spaced from the bottom surface30 of the central portion 26, the longitudinal wires 16 are embedded inthe narrow intermediate portions 28 and the free end portions 20 extendupwardly into the side portions 27. Each portion 27 further includes aflat underside 31 and a downwardly extending flange 32.

Referring to FIGS. 3, 4 and 10, the frame 12 is generally U-shaped andhas side and front rails 13 that aremade of sheet metal and aregenerally U-shaped in cross section to define a horizontal top wall 33,a generally vertical wall 34 and a generally horizontal bottom wall 35.The body 25 is dimensioned such that the intermediate portion 28 andsurface 31 engage the top wall 33 while the flange 32 engages the outersurface of the side wall 34. 7

Referring to FIG. 8, the body 25 of foam plastic material furtherincludes cut-away portions 35 in the intermediate portion 28 that defineaccess to the longitudinal wires 16.

Further in accordance with the invention, the upholstery fabric 36 isapplied to the outer surface of the portions 26, 27 as shown in FIG. 7with portions of the fabric extending downwardly through groove: 29 andfastened to the wire 16 by pulling portions of the fabric through theopenings 35' and fastening them to the wire either by sewing, clampingor other means.

Another portion. of the fabric is pulled over portion 27 downwardly asat 38 along the side wall 34 and bottom wall 35 and connected by rings39 through openings 40 in the bottom wall.

As shown in FIG. 9, a transverse groove 41 is provided in body 25overlying but spaced from an intermediate portion 19 of transverse wire18 to define a front portion 42. The upholstery extends into this groove41 and is fastened to the intermediate portion 19 by a' sewing, clampingor other means through openings 43 (FIG. 2).

It has been found that the fastening of the covering 38 to the framecombined with the engagement of the flange 32 with the wall 34 providessufficient confinementfor the body 25 such that the body need not befastened by any means directly to the frame.

In operation, it has been found that by supporting the body 25 directlyon the seat frame, a firm, yet resilient, support is provided withoutthe need for resilient springs and without the usual bouncing orcontinual spring action that occurs in conventional seats.

In accordance with the invention, the primary sup port for the seat ison the wall 33 wherein wires 16 overlie the wall but are spacedtherefrom by a thin later of foam plastic material.

Although the body has been shown as being laterally confined by a flange32 engaging the outer surface of the frame, it can be readilyappreciated that lateral confinement or restraint might be obtained by aflange engaging an inner portion of the frame.

The construction of the seat back 1 l is similar to that of the seatbase 10.

In each of the forms of the invention, the foam material may be castabout the spring assemblies with the free portions entirely embedded inthe foam material, the outer configuration of the foam materialsimulating the final shape of the seat;

By varying the inclination of the free portions of the I transversewires with respect to the intermediate portions, a varying shape andfeel may be provided to the seat'back and seat base. Similarly, byvarying the configuration of the sinuous elements, varying degrees ofresiliency may be achieved.

I claim: 1. In a seat construction, a spring assembly comprising a pairof longitudinally extending wires, a plurality of transversely extendingspaced spring wires,

at an acute angle to the intermediate portion, an additionallongitudinally extending wire connecting the free ends of saidtransversely extending spring wires along each said first-mentionedlongitudinally extending wire, I

a body of foam plastic material in which substantially the entire springassembly is embedded,

a frame comprising spaced side rails,

said body and said frame having interengaging portions to providelateral confinement for said body, said longitudinally extending wiresoverlying and spaced from portions of said side rails.

2. The combination set forth in claim 1 wherein said intermediateportions of said spaced wires are substantially adjacent but spaced fromone surafac of said body.

3. The combination set forth in claim 1 including a border wireconnecting said second-mentioned longitudinally extending wires.

4. The combinationset forth in claim 1 wherein said bodyincludes'longitudinally extending grooves in the upper surface thereofoverlying said longitudinally extending wires.

5. The combination set forth in claim 1 including upholstery materialoverlying said body and connected to said frame, said material providingthe sole means for preventing movement of said body outwardly withrespect to said frame.

6. The combination set forth in claim 5 including longitudinallyextending grooves in said body overlying and spaced from said pair oflongitudinally extending wires, said upholstery material extending intosaid grooves and means fastening said material to said wires.

7. The combination set forth in claim 5 including a transverse groove,in said body overlying and spaced from an intermediate portion of atransverse wire, said upolstering material extending into said groove,and means fastening said material to said intermediate portion.

. 8.'The combination set forth in claim 6 wherein said I body of foamplastic material includes portions of said body cut away to provideaccess to said pair of longitudinally extending wires.

9. The combination set forth in claim 1 wherein said interengaging meansbetween said body and said frame comprises a first extending surfacewhich said firstmentioned longitudinally extending wire overlies and asecond surface at an angle thereto, said body having portions thereofengaging said surfaces.

10. The combination set forth in claim 9 wherein said second surfacefaces outwardly.

I l I i i

1. In a seat construction, a spring assembly comprising a pair oflongitudinally extending wires, a plurality of transversely extendingspaced spring wires, portions of said transversely extending spacedspring wires being wound around said longitudinally extending wires todefine an intermediate portion extending between the spacedlongitudinally extending wires and connected thereto and free endsextending beyond the longitudinally extending wires at an acute angle tothe intermediate portion, an additional longitudinally extending wireconnecting the free ends of said transversely extending spring wiresalong each said first-mentioned longitudinally extending wire, a body offoam plastic material in which substantially the entire spring assemblyis embedded, a frame comprising spaced side rails, said body and saidframe having interengaging portions to provide lateral confinement forsaid body, said longitudinally extending wires overlying and spaced fromportions of said side rails.
 2. The combination set forth in claim 1wherein said intermediate portions of said spaced wires aresubstantially adjacent but spaced from one surface of said body.
 3. Thecombination set forth in claim 1 including a border wire connecting saidsecond-mentioned longitudinally extending wires.
 4. The combination setforth in claim 1 wherein said body includes longitudinally extendinggrooves in the upper surface thereof overlying said longitudinallyextending wires.
 5. The combination set forth in claim 1 includingupholstery material overlying said body and connected to said frame,said material providing the sole means for preventing movement of saidbody outwardly with respect to said frame.
 6. The combination set forthin claim 5 including longitudinally extending grooves in said bodyoverlying and spaced from said paIr of longitudinally extending wires,said upholstery material extending into said grooves and means fasteningsaid material to said wires.
 7. The combination set forth in claim 5including a transverse groove in said body overlying and spaced from anintermediate portion of a transverse wire, said upholstering materialextending into said groove, and means fastening said material to saidintermediate portion.
 8. The combination set forth in claim 6 whereinsaid body of foam plastic material includes portions of said body cutaway to provide access to said pair of longitudinally extending wires.9. The combination set forth in claim 1 wherein said interengaging meansbetween said body and said frame comprises a first extending surfacewhich said first-mentioned longitudinally extending wire overlies and asecond surface at an angle thereto, said body having portions thereofengaging said surfaces.
 10. The combination set forth in claim 9 whereinsaid second surface faces outwardly.